Making a durable (removable) upper/lower grille block for the UFO: 2000 Honda Insight

[MetroMPG]

Well, I wasn't able to make an idiot proof part:

• I mixed/brushed on epoxy over the foam (maybe 2 coats);
• then sanded it and finished with bondo and spot putty;
• then high fill primer/sand/prime/sand/prime.

It was quite a respectable looking job after priming.

But since then I had bubbles appear in the finish. I hate doing finishing work.

[gijoe985]

Maybe I missed the post, but how did you end up mounting the lower block? Did it end up being no tools/removable like you wanted? I'm working on one for the vx now...

[MetroMPG]

The lower block was a no-tools installation/removal part.

The part was shaped to fit snugly in the lower opening. I attached bungee cords to the backside of the block and ran the cords straight back through the grille slats, then turned a 90 degree corner, upward to the rad support crossmember where I hooked them on.

That said, I never had to remove the part for cooling reasons.